Portable mold for erecting concrete or plastic shelters

ABSTRACT

The invention relates to a portable mold for erecting a poured concrete or plastic structure for use as a shelter or storage building. An inside inflatable form is used to develop an internal countour and supply a compressive force against a poured cement mix sandwiched between the inflatable form and an outside rigid form of determined contour, such as a quonset hut. The inflatable inner form can be removed after exhausting the compressed air from its confined area and may be reused.

United States Patent 1 Stickler, Jr.

[ 51 May 22,1973

1541 PORTABLE MOLD FOR ERECTING CONCRETE OR PLASTIC SHELTERS [76]Inventor: Charles W. Stickler, Jr., RD. No. 4,

Mohnton, Pa. 19540 [22] Filed: Mar. 3, 1970 211 Appl. No.: 16,109

[52] US. Cl ..425/405 H, 249/65 [51] Int. Cl ..B28b 3/00, B28b 7/32 [58]Field of Search ..249/65, 112, 97,

249/108, 96; 25/127 R, 128 D, 131 SC, 131 SD, 131 Z, 124; 264/31-34, 69,94; 18/5 P, DIG. 14; 52/2; 425/405 H [56] References Cited UNITED STATESPATENTS 3,592,436 7/1971 Chandler ..249/97 X 1,576,291 3/1926 Acker..249/108 2,579,801 12/1951 Crom et a1 ..25/127 R 3,206,155 9/1965Nottingham et al. ..25/124 X 1,964,386 6/1934 Nose ..249/65 X 3,128,5034/1964 Hahn et a1. ..25/127 X 2,311,358 2/1943 Baily ..24/128 D UX3,223,759 12/1965 Williamson ..l8/DlG. 14

2,892,239 6/1959 Neff ..25/DlG. 12

3,530,208 9/1970 Rausing l8/5 P X 1,600,353 9/1926 Nose ..249/65 X3,057,368 10/1962 Seaman ..249/65 UX 2,052,818 9/1936 Freyssinet et a1...25/128 K UX 2,823,442 2/1958 Nulle et a1 ..25/128 R X PrimaryExaminer-Robert D. Baldwin Attorney-William J. Ruano [57] ABSTRACT Theinvention relates to a portable mold for erecting a poured concrete orplastic structure for use as a shelter or storage building. An insideinflatable form is used to develop an internal countour and supply acompressive force against a poured cement mix sandwiched between theinflatable form and an outside rigid form of determined contour, such asa quonset hut. The inflatable inner form can be removed after exhaustingthe compressed air from its confined area and may be reused.

5 Claims, 4 Drawing Figures PATENIED I973 3, 734.670

SHEET 1 or 2 Fig.3.

CHARLES W. STICKLER JR.

VXWM/f his ATTORNEY Q; L. J' INVENTOR PORTABLE MOLD FOR ERECTINGCONCRETE OR PLASTIC SHELTERS This invention relates to a novel form forerecting a poured concrete or plastic structure for habitation, storage,or shelter.

An outstanding disadvantage of commonly used forms for erecting sheltersor huts has been that they are relatively complicated in design andgenerally comprised of parts that are not readily portable. Moreover,they are not flexible to permit easy variations in sizes and contours,as well as ease for inserting windows and door openings. Most important,they are not susceptible to quick assembly and very rapid erection ofthe concrete structure at the site.

An object of the present invention is to provide a novel form forerection of dwellings or large enclosures, which form is devoid of theabovenamed disadvantages.

A more specific object of the invention is to provide a novel portableform embodying essentially an inflatable inner form member surrounded bya rigid outer form in spaced relationship therewith which defines theoutside contour of the enclosure, and wherein a cement or plastic mix isintroduced between said forms and thereafter the inner form is inflatedso as to compress said mix and force it to assume the shape of the outerand inner surfaces of said forms.

Other objects and advantages will become more apparent from a study ofthe following description taken with the accompanying drawing wherein:

FIG. 1 is a top view of the form embodying the present invention;

FIG. 2 is a vertical, cross-sectional view thereof;

FIG. 3 is a partial end view thereof;

FIG. 4 shows a modification.

Referring more particularly to FIGS. 1, 2 and 3 of the drawing, a formis shown for erecting a poured concrete or plastic structure forhabitation, storage or shelter. The form illustrated, and by way ofexample, is somewhat the shape of a quonset hut.

The invention provides for easily erected and disassembled forms toreceive and compress semi-fluid structural material into calculatedshapes of predetermined dimension. The outside form may be of any simplegeometric shape composed of rigid panels 6 erected and clamped at 4 tofoundation footers 1, also clamped at 12, 13 at the top flanges ll ofthe panels with spacers 15 barely separating the respective joinedpanels at the ridge line.

An inside wall rigid retaining form 18 provides for a pre-determinedvertical height. The flange 19 of the rigid inside form is clamped at 20to the foundation footer 1 with rigidity and extends for the full lengthof structure on two sides. The distance between outer form panels 6 andthe inside wall retaining form 18 is architecturally calculated fromstructural requirements related to height and width of the completedstructure. Outside panels 6 may be flanged or formed at their joiningedge 7.

Reinforcement mesh 16 with spacers 17 common to the concrete process isspaced next to the outside form if structural design so requires it forstrength. A protective water retaining polyethylene sheeting 21 may beplaced between the reinforcement mesh 16 and the inflatable compressiveform 24 that is moved into the rigid erected form. The inflatable form24 is constructed of rubber or other elastic material so designed thatwhen filled with a pre-determined quantity of air at a required pressurea definite contour will be attained. Shape may be designed by insidehorizontal 28 and vertical 27 restrictors of webbing or other materials,and/or by vulcanized restrictive areas 26 in the body of the inflatableform in similar fashion to a bladder inflated in a football cover. Arestrictive envelope may be employed to insure contour. The form wouldbe rolled or folded into a manageable non-inflated mass for moving andstorage. The inflatable form would be equipped with inflating nozzleconnectors 25 and with an opening 29 to remove that condensed waterwhich may form and accumulate inside the form.

The purpose of the inflatable form 24 is to have it assume a structuralcontour somewhat less in dimension than the outside rigid form 6. Thedistance from the fully inflated inside form 24 to the rigid form 6would be greater near the foot and gradually decrease in thickness tothe ridge 11 or top of the combination of confining forms aspredesigned. Window and door shaping frames 22 may be placed as desiredbetween the two forms. The floor area 3 need but be level on earth 2 orit may be constructed prior to placement of the inside forms.

The inflatable form 24 is partially filled with compressed dry air sothat the shape and alignment is in correct relation to the rigid form 6.Once in alignment the form may be further inflated so that it hasassumed nearly full contour and begins to stretch out the adjacentpolyethylene sheeting 21. If sheeting is not used, a pre-shaped coveringof fabric, plastic, or other protective and confining envelope may beemployed to surround the inflatable form. An example is a leathercovered football which has a preformed inflatable bladder and a leathercover.

Insofar as the exterior form 6 encloses a cubic volume of known amountand the inside inflatable form occupies, when fully inflated, a knowncubic volume, then the difference would be that volume of space 30 to befilled with a selected material, such as cement and sand, concrete,plastic, or other structural material appropriate for architecturalpurposes.

End closures 9 may be pre-designed so that the panels may be clamped at8 to the perimeters of erected outside longitudinal forms. Theinflatable interior form 24 may then contour tightly against both endpanels. If elected, one end closure 9 may be prepared by design toreceive space allotment for cast-in-place concrete or other material.One or both ends 9 may be completed with pre-cast or pre-assembled endpanels for erection upon removal of the inflatable form. Retaining endpanels 9 may be reinforced with angles or other stiffening members 10 toresist the expanded inside form 24.

Semi-fluid cement, concrete, plastic or other structural material havingthe physical and/or chemical characteristics to solidify in reasonabletime may be pumped into the void space 30 through valve openings 23provided for the purpose. A sufficient volume is pumped into theconfined space at each panel to conform to calculated requirement. Theinflatable form 24 is then completely expanded to predetermineddimension by compressed dry air inflation. 'The expansion of the insideform will cause pressure to squeeze" and mold the semi-fluid material toexact dimension of the confining forms. The semi-fluid material wouldsqueeze upward pushing air, which is displaced,

through the opening 14 provided by the flange 15 separation at the ridgeline 11 of the joined outside forms. Semi-fluid material appearing atthe ridge line 11 would indicate proper air displacement. In some mixeshaving less fluid flow characteristics, the use of a vibrator againstthe outside form may improve the density of the material by reducing airentrapment.

All rigid outside forms 6,9 may be removed when the semi-fluid injectedmaterial has hardened to structural strength. The outside form clamps 8,12, 4 are removed first and the rigid forms 6 removed. At this time anyimperfect solidified area may be patch-filled with appropriate materialsand the outside contour brushed for texture of the appearance or paintedas desired.

The inside form 24 may now be partially deflated to relieve compressionagainst the structure sides and top and pulled from the inside area. Toassist in this removal and to reduce frictional resistance, polyethylenesheeting placed on the floor 3 at the time of form assembly willsimplify removable of the inflatable form. The outside components of theforms an the inflatable form may be moved to next erection site.

The inside wall rigid form 18 may now be removed and any necessary patchfilling of the inside structure may be completed. The polyethylene filmwill have served its purpose and been removed. The end walls 9 may beerected and joined to the roof and side structure by clamps 8. End walls9 may be of material, prefabricated or preformed, as the locale mayrequire and complete with doors, windows, ventilators, etc. Electrical,plumbing, or other service requirements may be pre-designed into thecomponents of the rigid forms.

Rigid forms may be coated on the inside with silicone, plastic, or suchother material to reduce adhesive tendencies of the cured cement orother structural material. Rigid panels may be of any suitable material,preferably light in weight. Clamps may be of any design preferably tofunction without the need of bolts requiring tools. Flange holes shouldbe slotted at 5 to make matching of pins and clamps 20, 4 simple inalignment. Spacers in the ridge flange 11 of the outside form 6 may bepermanently mounted to insure air venting during the injection of thestructural material.

Injection material may be of sand and cement, with or without additivesof stone or chemical and/or plastic compositions; or any other formulasor compositions which may be injected or placed in the forms andstabilized by chemical or physical means.

Not to be excluded is the use of this mold system to place treated oruntreated particles of sand or other solids which may then be injectedwith chemicals, stabilizers, plasticizers or hardening compounds of anykind.

FIG. 4 shows a modification of the invention. The most simple inflatableforms are the sphere and the cylinder for fabrication and handling withresultant lowest cost of manufacture.

Advantage of this possibility is taken by using an elongated cylinder. Afooter 31 encircles the area upon which the structure is to be erected.The shape of the footer may be of dual-depth, as shown, to resisthorizontal movement, such as from sea pressures, or may be flat forhousing units. Anchoring pins 32 are cast in the footer 31 in U shapefor anchoring the forms and 37.

An inflatable cylindrical form 34 of neoprene, rubber or other flexiblematerial is placed on the midcenterline of the parallel footers 31. Ashaping form 36 of light-weight material (possibly an inflatable member)is then placed along the length of form 34 and adjacent the row of pins3221.

A shaping blanket or form 35 is placed over the in flatable form 34 andshaping form 36 and firmly fastened at the tie pins 3211.

Air pressure applied to the inflatable form 34 will cause the form toexpand into the shape of a cylinder and exert pressure against shapingform 36 and against shaping blanket 35 to cause a desired geometricalshape to be formed. This will be the basis of the desired inside formingwhich will compress fluid cement mix (or other materials) in spaceagainst outer form 37.

The outer restricting form 37 may be erected lengthwise in convenienthandling panels tied at the base to footer 31 and fastened temporarilyat tie-pin 32b. Opposite panels are fastened by temporary clamps 38 atthe top flange of each paired panel as shown. Air and excess fluidcement may escape at the top formed flange by design of the flange. Eachpanel may be provided with a valve or opening 39 to permit flow of fluidcement (or other material) to be injected in measured quantity betweenthe inner inflatable form comprising 34, 35, 36 and the outerrestrictive form 37.

In operation, the inside inflatable form 34, 35, 36 would be airinflated almost to full pressure and not quite to full pre-determineddimension. At each end of the assembled forms, a pressure resistantclosing form would be firmly clamped or fastened to the outsiderestricting form to provide a totally enclosed vessel. A pre-determinedquantity of fluid cement is injected through openings 39 into space 40between inflatable form 34, 35, 36 and the outer restricting form 37.Windows (not shown) may be formed such as by use of elements 22 shown inFIG. 2.

Full determined air-pressure is now applied to the inflatable form 34,35, 36 to compress the fluid cement into the space 40 of fixed geometricsize between inner and outer dimensioned forms. Air may escape along theupper flange area of the outer forms and any excess cement will extrudeat that escape also. During the compression operation, the cement mixmay be vibrated by applying vibratory means against the outer form 37.

Upon completion of curing time, the outer forming panels and endclosures may be removed for re-use at a new site. The inner inflatableform 34, 35, 36 deflated are also removed to a new site. Pre-formed endpanels may then be fixed to the structure to provide full enclosure.

Additional provisions may include the following:

The area 33 of floor space between the footers may be hard packed sandor earth. An alternate may include a full cement slab as a floor.

In some areas the structure may be cast as a "groin" for placementwithout the need of footers. The footers would then be used merely forcasting purpose and reused for additional structures and the groinsmoved and placed as required.

If the footers are to be an integral part of the structure, thenreinforcement rods and a lock-in cast should be provided in the footer.

It is not intended to exclude the provision of an integral footer andstructure casting including a cast floor.

Metal reinforcement may be set in place, or reinforcing fibers added tothe cement mix at the time of mix preparation.

An inner free-floating metal shaping blanket 35 may be used instead ofthat described as a flexible (nylon or other similar material) shapingmember. The inflatable member 34 would then pneumatically lift the metalblanket to form position.

It is possible to provide at least one end with this casting procedureby providing a compression area at the one end. A slip forming operationemploying this method may be used for continuous casting of thestructure.

A variety of cast-in-place geometrical forms may be utilized to providefor highway culverts and other structures common to the constructionindustry.

Thus it will be seen that I have provided an efficient and highlyportable form for erecting dwellings or large enclosures at the site byexpanding an inner partition pneumatically against a poured mix which issandwiched between an inner form and an outer rigid form whereby the mixbecomes uniformly distributed and compressed between the forms, andwhich forms are easily removed and used over and over again.

While I have illustrated and described several embodiments of myinvention, it will be understood that these are by way of illustrationonly and that avarious changes and modifications may be made within thescope of the present invention and the following claims.

I claim:

1. A form for erecting building shells or enclosures, comprising anouter rigid curved form sub-divided into two curved complementary halvesterminating in upwardly extending flanges which are in confrontingrelationship, said halves defining the outer wall, a base, means fordetachably fastening said flanges together,

means for detachably fastening the bottom end portions of said halves tosaid base, a flexible inner form spaced inwardly from and surrounded bysaid outer form, means for anchoring the ends of said flexible innerform to said base, means for allowing introduction of cementious mixbetween said inner and outer forms, a cylindrical tube of inflatablematerial substantially surrounded by said inner form and in contact withsubstantially the top half thereof and means for introducing air underpressure inside said cylindrical tube so that it will inflate andcompress said mix between said inner and outer forms.

2. A form as recited in claim 1 wherein there is a space ofsubstantially triangular cross-section between the bottom half of saidcylindrical tube and each end portion of said inner form, a shaping formsubstantially filling each of said spaces, whereby said shaping formswill press outwardly against said inner form upon inflation of saidcylindrical tube.

3. A form as recited in claim 1 wherein said flanges are disposed inspaced confronting relationship when fastened together, whereby saidcementious mix will overflow therebetween to define a medial rib.

4. A form as recited in claim 1 wherein said cylindrical tube is ofelastic rubber material, wherein said base is in the form of a footer,and wherein said means for detachably fastening the bottom end portionof said halves to said base and said means for anchoring the ends ofsaid flexible inner form to said base comprise a plurality of U-shapedelements embedded in said base and having upstanding legs which serve asthe respective means.

5. A form as recited in claim 2 wherein said shaping form is inflatable.

1. A form for erecting building shells or enclosures, comprising anouter rigid curved form sub-divided into two curved complementary halvesterminating in upwardly extending flanges which are in confrontingrelationship, said halves defining the outer wall, a base, means fordetachably fastening said flanges together, means for detachablyfastening the bottom end portions of said halves to said base, aflexible inner form spaced inwardly from and surrounded by said outerform, means for anchoring the ends of said flexible inner form to saidbase, means for allowing introduction of cementious mix between saidinner and outer forms, a cylindrical tube of inflatable materialsubstantially surrounded by said inner form and in contact withsubstantially the top half thereof and means for introducing air underpressure inside said cylindrical tube so that it will inflate andcompress said mix between said inner and outer forms.
 2. A form asrecited in claim 1 wherein there is a space of substantially triangularcross-section between the bottom half of said cylindrical tube and eachend portion of said inner form, a shaping form substantially fillingeach of said spaces, whereby said shaping forms will press outwardlyagainst said inner form upon inflation of said cylindrical tube.
 3. Aform as recited in claim 1 wherein said flanges are disposed in spacedconfronting relationship when fastened together, whereby said cementiousmix will overflow therebetween to define a medial rib.
 4. A form asrecited in claim 1 wherein said cylindrical tube is of elastic rubbermaterial, wherein said base is in the form of a footer, and wherein saidmeans for detachably fastening the bottom end portion of said halves tosaid base and said means for anchoring the ends of said flexible innerform to said base comprise a plurality of U-shaped elements embedded insaid base and having upstanding legs which serve as the respectivemeans.
 5. A form as recited in claim 2 wherein said shaping form isinflatable.